Integrated Hot Tub, Spa, or Pool and Frame and Method of Inground Installation

ABSTRACT

An assembly of in-ground tub with an attached frame is provided, and a method of installing the same. The tub is mounted within the frame. A lower surface of the tub, which may be inclined relative to the bottom surface of the frame, is retained above such bottom surface so that the bottom surface of the frame can remain horizontal while the lower surface of the tub is inclined. The tub and attached frame are installed by digging a hole in the ground, inserting the tub with attached frame into the hole, pouring a first layer of concrete into the hole, at least partially filling the hole with dirt, and optionally pouring a second layer of concrete to support decking near an entrance to the tub.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates broadly to the field of in-ground tubs. More specifically, this invention relates to an in-ground installable tub and frame, and a method for installing the tub.

2. State of the Art

Hot tubs, swim spas, and pools (hereinafter, ‘tubs’) are frequently installed outside so that they can be used for personal enjoyment, exercise, physical therapy, and entertaining others. Hot tubs, swim spas, and pools can create a positive atmosphere or ambience, which is enhanced by their outdoor use during the day or at night, and by their installation in the ground rather than above it. In addition, in-ground pools and hot tubs have an aesthetic appearance, which has made them very popular. Installing hot tubs in the ground has historically involved digging a hole in the ground to accommodate the hot tub, mounting the hot tub on the bottom surface of the hole, and filling in the hole with dirt, concrete, or other filler/support materials. Many modern hot tubs have sloped bottom surfaces in order to facilitate drainage and/or to change the water line level within the tub. Modern hot tubs also frequently have steps formed directly into the sidewall, which sometimes requires a sloped bottom surface. When at least a portion of the lower surface of the tub is inclined, the ground at the bottom of the hole needs to be similarly inclined so that the tub will mount flush to it. Otherwise, the tub may not properly align with the ground. Grading the bottom of a hole in the ground at a specific angle over one or more sections to match the bottom of the tub is an arduous task that requires the use of expensive machinery, skilled operators, and increased installation times and cost.

SUMMARY OF THE INVENTION

The present invention is directed to an in-ground tub assembly and a method for installing the same. The in-ground tub assembly includes a tub and an attached frame. The frame externally mounts, supports, and positions the tub as it is installed in the ground. The tub is mounted to the frame, and the frame is placed on a horizontal surface (the easiest type to create) at the bottom of a hole dug into the ground. At least a portion of the bottom of the tub is inclined and not parallel with the horizontal surface. The frame is designed to accommodate the tub's incline by initially supporting and positioning the tub above the horizontal surface.

A hole is excavated in the ground with a flat, horizontal, bottom surface. The tub assembly is inserted into the hole such that the base of the frame rests horizontally on the bottom surface of the hole. At this point, at least a portion of the tub's bottom surface is retained above the ground surface at the bottom of the hole, creating a gap therebetween. A layer of concrete is provided into the hole until the concrete at least partially fills the gap between the lower surface of the tub and the bottom surface of the hole, thus forming a solid foundation for the tub and supporting the frame. The present invention thus simplifies the tub installation process where the tub has an inclined bottom surface and is to be installed in the ground. The present invention eliminates the need for creating a graded or sloped surface conforming to the shape of the bottom of the tub.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the in-ground tub assembly.

FIG. 2 is an exploded schematic view of the in-ground tub assembly of FIG. 1.

FIG. 3 is a side view of the in-ground tub assembly of FIG. 1.

FIG. 4 is a top schematic view of the installation of the in-ground tub assembly of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-4 show a ground installable tub assembly 10. The tub assembly 10 includes a tub 12 and a frame 14 that externally mounts, supports, and positions the tub 12 within the frame 14. The frame 14 has a base 16, a top section 18, and a plurality of vertical side supports 20 that connect the base 16 to the top section 18. The side supports 20 are preferably located four feet apart or where needed. The base 16 of the frame 14 is horizontal, planar, and preferably has two side members 22 a and two end members 22 b that connect to form the perimeter of a rectangle. The top section 18 is also horizontal, planar, and preferably has two side members and two end members, collectively 24, that preferably connect to form the perimeter of a rectangle parallel to the base 16. The side supports 20 preferably extend perpendicular between the base 16 and the top section 18. In the preferred embodiment, the base 16, the side supports 20, and the top section 18 form the border of a generally rectangular compartment in which the tub 12 is mounted.

The frame 14 preferably has an array of deck supports 26 attached to the side supports 20 for supporting decking 70 around the perimeter of the tub 12. The deck supports 26 attach to top portions 20 a of each of the side supports 20 just beneath the top section 18 of the frame 14, and project away from the generally rectangular compartment. The deck supports 26 preferably angularly attach to the side supports 20 such that the supports 26 have a slight downward incline away from the tub 12, preferably at a one to four degree angle. The downward incline helps to direct water away from the tub 12 and frame 14 that comes from spillage from the tub 12, rainfall, or some other water source such as a sprinkler. The length of each deck support 26 is preferably between thirty-six to forty-eight inches, with an optimal length of thirty-six inches.

In one embodiment, the deck supports 26 alone support the decking 70, and are thus cantilevered from the side supports 20. In this embodiment, it is recommended that when the tub 12 and frame 14 are installed in a hole in the ground (further discussed below), that the hole be filled with dirt 64 up to the level of the deck supports 26 to provide additional support.

In the preferred embodiment, each deck support 26 is preferably provided with a brace 28 that extends to the associated side support 20. The braces 28 are used in conjunction with the deck supports 26 to support the decking. The braces 28 angularly attach to bottom portions 20 b of the side supports 20. Each brace 28 extends up to attach to a corresponding deck support 26. The deck supports 26, braces 28, and side supports 20 thus together form a truss used to support the decking 70. The length of the braces 28 is sized to accommodate the height and angle desired for the decking 70. The deck supports 26 are preferably attached to the frame 14 around the entire perimeter of the tub 12, with two supports attached to the corner side supports generally at a right angle to one another. The base 16, top section 18, and side supports 20 may be attached to form the frame 14 by a plurality of nuts and bolts, welding, or other mechanical means. In the preferred embodiment, the frame 14 is welded together, and nuts and bolts are additionally used to attach the corners of the frame 14 and the deck supports 26.

In the preferred embodiment, the frame 14 (including the base 16, top section 18, side supports 20, deck supports 26, and braces 28) is made from noncorrosive galvanized angle iron. The noncorrosive angle iron will prevent the frame 14 from rusting in an in-ground environment. In addition, as angle iron is structurally strong and has no hollow interior portion, it will not allow ground water to collect inside the frame 14.

Once the frame 14 is assembled, the tub 12 is mounted into the frame, preferably in a factory environment. The tub 12 has a lower surface 32, a sidewall 34 integrally formed with the lower surface 32, and an upper rim 36 integrally formed with the sidewall 34. The sidewall 34 of the tub 12 projects upward from the lower surface 32 of the tub 12 and ends at the upper rim 36. In the preferred embodiment, the tub 12 is a swim-spa style tub having an interior portion 38 with a swimming area 39 where users can swim against a current that is achieved through a number of jets 50 or other water current generator. The interior portion 38 also includes a number of seats 40 arranged around the perimeter of the swimming area 39 preferably at least partially defined by a step 35 in the sidewall of the tub. The seats 40 are optionally provided with additional hydrotherapy jets 50. At one end of the tub 12, the sidewall 34 defines stairs 44 comprising a plurality of steps 44 a between the upper rim 36 and the lower surface 32. In the preferred embodiment, the tub dimensions are eight feet wide, twenty feet long, and four feet deep at its deepest location. The lower surface 32 of the tub 12 is preferably inclined to guide water toward a drain, as well as optionally to maintain different water levels within the interior portion 38 of the tub 12. The lower surface 32 of the tub 12 is thus typically not parallel with the horizontal base 12 of the frame 14.

The tub 12 preferably has an acrylic reinforced with fiberglass. The acrylic tub shape may be vacuum formed to shape and then strengthened with fiberglass about an exterior surface thereof. A gel coat surface may also be used in conjunction with the fiberglass.

A hydrotherapy system 49 is preferably provided to the tub 12. The hydrotherapy system 49 includes a plurality of jets 50 situated within the sidewall 34, a suction fitting 52, associated plumbing 54, and a water pump 56 to circulate water out of the tub 12 through the suction fitting 52, through the plumbing 54, and back through the jets 50 under pressure back into the tub 12. As is well known in the art, as the water is sent to the jets 50 it is moved through a venturi in the jets 50 where air from a supply is entrained within the water such that when the water is ejected by the jet 50, it may be aerated. The tub 12 also preferably includes a skimmer 58 at water level to filter the water. The tub 12 may also be plumbed for connection to a water supply.

The tub 12 is lowered into the frame 14. The lower surface 32 of the tub 12 passes through the top section 18 of the frame and into the rectangular compartment defined by the frame 14. In an assembled configuration, the upper rim 36 of the tub 12 overlaps the side and end members 24 of the top section 18 and the lower surface 32 and sidewall 34 of the tub 12 are retained within the rectangular compartment defined by the frame 14 while the upper rim 36 grips the top section 18. The tub 12 is thus suspended within the frame 14 with the weight of the tub 12 being transferred to the frame 14 through the upper rim 36. The upper rim 36 is mechanically coupled to the top section 18 by bolts, sets screws, adhesives, bonding agents, and/or other means.

In the preferred embodiment, epoxy is used to seal a plurality of intermediary pieces 48 under the upper rim of the tub 12 before it is lowered onto the frame 14. The intermediary pieces 48 have a number of threaded holes for receiving bolts that attach the intermediary pieces 48 to the top section. The frame 14 is dimensioned to retain the lower surface 32 of the tub 12 above the base 16 of the frame 14 in the assembled configuration. When the tub 12 has stairs 44 defined by the sidewall 34, the frame 14 preferably has two diagonal side supports 21 that angularly attach between the end members 22 b of the base 16 and project upward from the base 16 to angularly attach to an end of the top section 18. The frame 14 has a plurality of step supports 46 corresponding to the steps 44 a. The step supports 46 run underneath the steps 44 a and mechanically connect to the diagonal side supports 21 on opposite sides of the steps 44 a.

Temporary wooden or metal planks 60 may optionally be installed under the lower surface 32 of the tub to provide additional support to the tub 12 while it is being shipped to the installation location. These planks are removed from between the tub 12 and the frame 14 prior to installing the tub assembly 10. The tub assembly 10 installation is discussed below.

The assembly 10 is transported to an install site. At the install site, a hole is excavated in the ground to accommodate the tub assembly 10. The hole should be leveled at the bottom to form a flat horizontal bottom surface. A flat horizontal surface is substantially easier to create than one requiring a specific non-horizontal grade or a complex shape to support the undersurface of the tub. Any temporary support planks 60 are removed, and the tub assembly 10 is then lowered into the hole such that the base 16 of the frame 14 rests on, and is parallel with, the horizontal bottom surface. At this point, at least a portion of the lower surface 32 of the tub 12, and generally the entirety thereof, is disposed above the bottom surface, thereby defining a gap, and the tub 12 is still supported by the frame 14. The weight of the tub 12 is transmitted to the top section 18 of the frame 14 through the upper rim 36. The side supports 20 transfer the weight from the top section 18 to the base 16. The base 16 is supported by the bottom surface of the ground.

Once the tub assembly 10 is positioned within the hole, a first layer of concrete 66 is poured into the hole. The first layer of concrete 66 at least partially fills the gap between the bottom surface and the inclined lower surface 32 of the tub 12, thus forming a solid foundation for the tub 12 that supports the weight of the tub 12. If the layer of concrete 66 fully fills the gap, then the frame 14 at that point will no longer be supporting the tub 12. If a portion of the gap remains after the concrete 66 is poured, then the frame 14 may sustain a portion of the weight of the tub 12.

At least a portion of the remainder of the hole is then filled with dirt 64. In the preferred embodiment, the entire remainder of the hole is filled with dirt 64. A wire mesh or rebar 62 is preferably provided across the decking supports 26. A second layer of concrete 68 is optionally poured over the mesh or rebar 26 on the decking supports 26. As mentioned above, decking 70 (e.g. wood, wood substitute, or a finished layer of the poured second layer of concrete 68) may optionally be provided to the poured second layer 68. If the dirt 64 and/or concrete 68 is poured to a level higher than that of the decking supports 26, then the inclined decking supports, 26 will facilitate keeping the dirt 64 and concrete 66 at the desired incline away from the tub assembly 10. Alternatively, decking 70 may be applied directly to the decking supports 26 without first pouring a concrete 66 layer or without the use of wire mesh or rebar 62 extending across the decking supports 26.

Several stages of the installation process are illustrated with reference to FIG. 4. The bottom of FIG. 4 shows first, second, third, and fourth areas (72, 74, 76, 78) defined between the deck supports 26. The first area 72 shows the first layer of concrete 66 that has been poured between the bottom surface of the hole and the inclined lower surface 32 of the tub 12. The second area 74 shows dirt 64 that has been backfilled into the hole covering the first layer of concrete 66. The dirt 64 is filled approximately as high as the deck supports 26. The third area 76 shows wire mesh or rebar 62 placed over the dirt 64 on top of or between the deck supports 26. The fourth area 78 shows the second layer of concrete 68 that has been poured on top of the dirt 64 and wire mesh/rebar 62, and the decking 70 that has been placed over the second layer of concrete 68. The remainder of FIG. 4 illustrates a top view of the preferred embodiment prior to the second layer of concrete 68 and decking 70 being installed.

According to another embodiment of the invention, the frame and tub are transported disassembled from each other to the installation side. The level hole is excavated in the ground, the frame is inserted into level in the hole. The tub is then inserted into the frame and secured thereto. The remainder of the method is the same as described above.

The present invention and method reduces the time and cost associated with installing and implementing a tub into the ground by eliminating the laborious task of grading or sloping a foundation parallel with the bottom of the tub. Using the present invention, hot tubs having differently sloped or shaped lower surfaces can easily be installed in the ground using a standard hole with a horizontal grade. The sloped decking supports will allow for easy access to the tub, provide water drainage away from the tub, and create an aesthetic appearance consistent with the tub setting.

There have been described and illustrated herein several embodiments of an installable tub with an attached frame, and methods installing the same. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular materials, dimensions, and a particular tub design have been disclosed, it will be appreciated that other suitable substitutes and methods can be used and applied to other tubs. For example, while angle iron has been recommended, it will be understood by those skilled in the art that other suitable materials can be used to create the frame. While a rectangular shaped frame has been disclosed, it will be appreciated that other shapes can be utilized. In addition, while stairs have been disclosed that are integrally formed from the sidewall of the tub, it will be appreciated that other types of stairs or ladders may be attached internally or externally to the tub. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed. 

1. An in-ground tub assembly, comprising: a frame comprising a base, a plurality of side supports, a plurality of deck support members, and a top section, said base being generally planar and having a perimeter, said plurality of side supports projecting upward from said base around the perimeter, said top section being mechanically coupled to said plurality of side supports, and said plurality of deck support members being mechanically attached to said side supports and extending outward from said frame; and a tub comprising a lower surface, a sidewall integrally formed with said lower surface, and an upper rim integrally formed with said sidewall, said sidewall projecting upward from said lower surface and ending at said upper rim, said upper rim being coupled to said top section of said frame such that said tub is supported by said frame, wherein at least a portion of said lower surface of said tub is inclined relative to said base.
 2. The in-ground tub assembly of claim 1, wherein: said at least one of said deck support members projecting from said top end of said corresponding side supports extends outward from said frame at a downward angle.
 3. The in-ground tub assembly of claim 1, wherein: said deck supports extend downward relative to said top section at an angle of 1° to 4°.
 4. The in-ground tub assembly of claim 1, wherein: said lower surface of said tub is retained above said base of said frame.
 5. The in-ground tub assembly of claim 1, wherein: each of said plurality of side supports has a top end and a bottom end, at least one of said deck support members projects from adjacent said top end of one of said side supports, and at least one of said deck support members projects from said bottom end of a corresponding one of said side supports.
 6. The in-ground tub assembly of claim 1, wherein: said deck support members are spaced approximately four feet apart from each other.
 7. The in-ground tub assembly of claim 1, wherein: said deck support members are made from galvanized angle iron.
 8. The in-ground tub assembly of claim 1, wherein: said base, said plurality of side supports, and said top section define a generally rectangular compartment.
 9. The in-ground tub assembly of claim 1, further comprising: a hydrotherapy system for circulating and pressurizing water, said hydrotherapy system including a plurality of jets situated within said sidewall of said tub, and a water pump for circulating the water.
 10. The in-ground tub assembly of claim 9, wherein: said tub has dimensions of at least eight feet wide and twenty feet long.
 11. An in-ground tub assembly, comprising: a frame comprising a base, a plurality of side supports, and a top section, said base being generally planar and having a perimeter, said plurality of side supports projecting upward from said base around the perimeter, and said top section being mechanically coupled to said plurality of side supports; and a tub comprising a lower surface, a sidewall integrally formed with said lower surface, and an upper rim integrally formed with said sidewall, said sidewall projecting upward from said lower surface, ending at said upper rim, and forming a plurality of stairs disposed between said upper rim and said lower surface, each of said plurality of stairs having a step surface formed to be generally parallel with said lower surface, said upper rim being coupled to said top section of said frame such that said tub is supported by said frame, wherein at least a portion of said lower surface of said tub is inclined relative to said base.
 12. The in-ground tub assembly of claim 11, wherein: said base, said plurality of side supports, and said top section define a generally rectangular compartment.
 13. The in-ground tub assembly of claim 11, wherein: said frame further includes at least one stair support extending horizontally underneath a respective step of said stairs such that each said stair support supports said respective step.
 14. The in-ground tub assembly of claim 11, further comprising: a hydrotherapy system for circulating and pressurizing water, said hydrotherapy system including a plurality of jets situated within said sidewall of said tub, and a water pump for circulating the water.
 15. An in-ground tub assembly, comprising: a frame made from a plurality of noncorrosive metal supports comprising a base, a plurality of side supports, and a top section, said base being generally planar and having a perimeter, said plurality of side supports projecting upward from said base around the perimeter, and said top section being mechanically coupled to said plurality of side supports; and a tub comprising a lower surface, a sidewall integrally formed with said lower surface, and an upper rim integrally formed with said sidewall, said sidewall projecting upward from said lower surface and ending at said upper rim, said upper rim being coupled to said top section of said frame such that said tub is supported by said frame, wherein at least a portion of said lower surface of said tub is inclined relative to said base.
 16. The in-ground tub assembly of claim 15, wherein: said plurality of noncorrosive metal supports include galvanized angle iron.
 17. The in-ground tub assembly of claim 15, wherein: said base, said plurality of side supports, and said top section define a generally rectangular compartment.
 18. The in-ground tub assembly of claim 15, further comprising: a hydrotherapy system for circulating and pressurizing water, said hydrotherapy system including a plurality of jets situated within said sidewall of said tub, and a water pump for circulating the water.
 19. An in-ground tub assembly, comprising: a frame made from a plurality of noncorrosive metal supports comprising a base, a plurality of side supports, and a top section, said base being generally planar and having a first lower surface and a perimeter, said plurality of side supports projecting upward from said base around the perimeter, and said top section being mechanically coupled to said plurality of side supports; and a tub comprising a second lower surface, a sidewall integrally formed with said second lower surface, and an upper rim integrally formed with said sidewall, said sidewall projecting upward from said second lower surface and ending at said upper rim, said upper rim being coupled to said top section of said frame such that said tub is supported by said frame, wherein said second lower surface of said tub is retained above said first lower surface of said base.
 20. The in-ground tub assembly of claim 19, further comprising: a hydrotherapy system for circulating and pressurizing water, said hydrotherapy system including a plurality of jets situated within said sidewall of said tub, and a water pump for circulating the water.
 21. A method for installing an in-ground tub, comprising: a) providing an assembly of a frame supporting an a outdoor tub, the frame defining a flat lower base, the tub defining a non-flat lower surface at least partially suspended relative to the flat lower base, and the tub provided with a hydrotherapy system; b) excavating a hole in a ground, the hole having a level bottom surface and dimensioned to accommodate the assembly; c) inserting the assembly into the hole such that the lower base of the frame rests horizontally on the bottom surface and a gap is defined between the lower surface of the tub and the bottom surface of the hole; d) providing a first layer of concrete into the hole until the concrete at least partially fills the gap between said lower surface of the tub and the bottom surface of the hole.
 22. The method of claim 21, wherein: after said inserting, the lower surface of the tub is provided at an incline relative to the bottom surface of the hole.
 23. The method of claim 21, further comprising: providing dirt into the hole to at least partially fill in the hole about the frame and tub.
 24. The method of claim 23, further comprising: the frame has a top section and a plurality of deck support members projecting outward from the top section to support an amount of decking, and providing decking over said deck support members.
 25. The method of claim 24, wherein: said providing decking includes providing a second layer of concrete over the dirt and over the top section and said the of said deck support members. 